ok so i was bolting in the intake manifold on my rx-7 engine. as soon as i hit tension the bolt twisted and snapped. i'm still kicking myself for it. shoulda used new bolts for the engine stuff. lameo.

it broke off in a side housing... those are what, iron?

easy out didn't work either. the easy out broke off in the stuck bolt. i have a bolt with easy-out stuck in it, flush against the engine where i need to bolt down the intake manifold.

so anyway... the purpose of this thread is to recommend methods for me to extract the stuck bolt.

already thinking about:

1. taking it to a machine shop - it will cost $$ tho.
2. drilling it and re-tapping the hole.
3. tack welding a piece of scrap on the end of the stuck bolt and turning it out that way. this worries me as respects the expansion of the bolt when it's heated and potential damage from uneven heating of the motor itself. however the guy welding has done it for years at boeing and he is very good.

oh the bright side, the engine is out of the car.

 

well if the ezout wasn't broke in it then it could be removed with a left hand twist drill bit BUT the ezout is too hard to drill. Unless you can get the ezout out your gonna have a hard time.

 

can't remember the name of the process but I did the same thing last year. Engine was still in pieces (broke bolt on rear e-shaft seal) anyways we took it down to campus and they shot an electrode thing at it and got all the crap out. I think thats how it worked, can't remember actual name though. worked great just ran a thread chaser in it and worked great.

Ron

 

Weld a nut to the end of the broken stud and remove it with a suitable socket.
The heat of welding should expand the broken piece enough to loosten it. A bit of PB Blaster would be a good idea as well.
Dennis L. Cote